Antimicrobial Nonwoven Cloth, Preparation Method Thereof and Mask with the Antimicrobial Nonwoven Cloth

ABSTRACT

The present invention discloses an antimicrobial nonwoven cloth, whose raw materials comprising the following components in weight ratio: 75˜100 parts of polypropylene, 10˜25 parts of sodium p-styrenesulfonate, 10˜20 parts of silane coupling agent, 0.15˜1 part of polyhexamethylene biguanidine hydrochloride (PHMB), 0.05˜0.4 part of zinc salt, 1˜5 parts of bamboo charcoal fiber, and 0.01˜0.1 part of nano˜meter fumed silica. Further, a method of preparing the antimicrobial nonwoven cloth and a mask with antimicrobial nonwoven cloth are disclosed, to prevent bacteria from spreading through the air and saliva.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation Application of PCT Application No. PCT/CN2020/088655 filed on May 6, 2020, which claims the benefit of Chinese Patent Application No. 201910837529.1 filed on Sep. 5, 2019. All the above are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention generally relates to a technology of non-woven cloth, in particular to antimicrobial nonwoven cloth, preparation method thereof, and mask with the antimicrobial nonwoven cloth.

BACKGROUND

With increasing environmental pollution in modern society, there are more and more air pollutants, around 100 types. Air pollutants are mainly divided into harmful gases and particulate matters, which are caused by natural factors and human factors. The main factors are human factors, especially the pollutions caused by industrial production and transportation.

Haze is an aerosol system formed by water vapor and particulate matters in the atmosphere. Atmospheric particulate matter refers to a multiphase system mixture composed of solid or liquid particles suspended in the air. The atmospheric particulates are mainly from natural pathways and human activities. Natural sand and dust storms are the main source of coarse particles in the atmosphere, and natural activities such as volcanic eruptions may emit some atmospheric particles. The artificial sources of particulate matters mainly include various combustion reactions, transportation and industrial processes, etc. There are obvious differences in damage to human body caused by fine particulate matters of different sources, properties and compositions. According to a study in the United States, for every 10 μg/m3 increase in the concentration of fine particulate matter from car exhausts, the total mortality rate increases by 3.4%; while the fine particulate matters mainly from the ground surface dust are not related to the total mortality rate.

The physical, chemical and optical properties of atmospheric particulates are closely related to the particle size, and their particle size can determine the atmospheric life of the particulate matters and the part and toxicity that they will eventually enter the human body. At present, the particle size of atmospheric particulates is generally represented by effective diameter, that is, the aerodynamic diameter. The total suspended particulates with a particle size of 10-100 μm cannot be breathed into the nasal cavity. The coarse particulates with a particle size of 2.5-10 μm mostly stay in the nasal and pharynx area. The fine particulates with a particle size of less than 2.5 μm, namely, the commonly known PM2.5, can reach the alveoli. The fine particulates have a small size and large surface area, and are absorbed with a large amount of organic pollutants, acid oxides, nano-quartz and other minerals, toxic heavy metals, bacteria and germs, etc., which can enter the human body through the respiratory tract, especially the ultrafine particulates of about 0.1 μm are deposited in the lungs, and even penetrate the alveoli to enter the blood circulation, causing most harm to human body. The dust collection efficiency of the mask is based on its blocking efficiency for fine dust, especially for respirable dust below 5 microns, since dust of this size can directly enter the alveoli, causing the most harm to human body. The dust blocking principle of ordinary gauze mask is mechanical filtering, namely, when the dust hits the gauze, it passes through multiple layers of barriers to block some large dust particulates in the gauze. However, some fine dust, especially dust less than 5 microns, will pass through the gauze meshes to enter the respiratory system.

When wearing the existing masks for a long time, viruses and germs are likely to accumulate on the masks. So the masks should be removed after two hours of use and cleaned and disinfected in time. The development of antimicrobial nonwoven cloth for the mask can open up a healthy way for humans to reject PM2.5.

SUMMARY

In view of the drawbacks of the prior art, an object of the prevent invention is to provide antimicrobial nonwoven cloth, preparation method thereof, and masks with the antimicrobial nonwoven cloth.

In order to achieve the foregoing object, the present adopts the following technical solution: an antimicrobial nonwoven cloth, whose raw materials comprising the following components in weight ratio: 75˜100 parts of polypropylene, 10˜25 parts of sodium p-styrenesulfonate, 10˜20 parts of silane coupling agent, 0.15˜1 part of PHMB, 0.05˜0.4 part of zinc salt, 1˜5 parts of bamboo charcoal fiber, and 0.01˜0.1 part of nano-meter fumed silica.

The present invention further discloses a preparation method of antimicrobial nonwoven cloth, comprising the following steps:

(1) Weighing: Weighing the following components in weight ratio: 75˜100 parts of polypropylene, 10˜25 parts of sodium p-styrenesulfonate, 10˜20 parts of silane coupling agent, 0.15˜1 part of PHMB, 0.05˜0.4 part of zinc salt, 1˜5 parts of bamboo charcoal fiber, and 0.01˜0.1 part of nano-meter fumed silica;

(2) Heating the weighed aqueous solution of polypropylene, sodium p-styrenesulfonate, silane coupling agent in a water bath to 60±2° C., keeping warm and stirring for 2.5±0.5 h, and carrying out UV irradiation for 15±2 min and then cool to 25±2° C. to obtain a polypropylene mixture;

(3) Preparing a composite solution using the weighed PHMB and zinc salt by the aqueous reaction method, then adding nano-meter fumed silica to obtain a composite antimicrobial agent; of which, using PHMB of different viscosity averaged relative molecular weights as a ligand, and adding zinc salt at a ratio of 5-6% to synthesize a stable micron-sized Zn-PHMB cationic complex from agglomerated small particles;

(4) Mixing the polypropylene mixture obtained in step (2) with bamboo charcoal fiber at 45±5° C. and stirring for 1±0.5 h, then adding the composite antimicrobial agent in step (3), stirring for 20±5 min and then standing for 1.5±0.5 h to obtain antimicrobial fiber solution, and then spinning to obtain antimicrobial nonwoven cloth fiber;

(5) Placing the antimicrobial nonwoven cloth fiber in step (4) on a mold for positioning and arrangement, and heat-pressing to form a fiber network structure;

(6) Adding anionic polyacrylamide solution as sizing liquid in the sizing machine, immersing the antimicrobial nonwoven cloth fiber web into the slurry with a temperature of 90±5° C. at a speed of 70±5 m/min, and then entering a drying room at a temperature of 135±5° C. for drying;

(7) After the sized and dried antimicrobial nonwoven cloth fiber web undergoes open-width treatment, performing desizing twice, washing out with warm water, and spraying ozone oil onto the web;

(8) Drying the desized fiber web qualitatively to prepare an antimicrobial nonwoven cloth product.

As a preferred embodiment, steps for preparing the bamboo charcoal fiber are as follows:

(1) Performing cleaning the raw material moso bamboo, and drying it at a temperature of 50±5° C. in a sterile environment, then evenly cutting and placing it in a carbonization furnace;

(2) Carrying out carbonization in a carbonization furnace under a pure oxygen high temperature environment by setting the initial firing temperature of the carbonization furnace at 400±50° C. and the initial firing time at 1±0.5 h; setting the calcination temperature of the carbonization furnace at 850±50° C. and the calcination time at 3±0.5 h; using nitrogen with a purity of 98% for barrier during the carbonization process;

(3) Obtaining the carbonized bamboo charcoal fiber product.

The present invention further discloses a mask with antimicrobial nonwoven cloth, comprising a mask body, a mask belt, and a nose strip, the mask body comprises at least one antimicrobial nonwoven cloth layer, and at least one filter cloth layer, and the antimicrobial nonwoven cloth layer is bonded with the filter cloth layer, the filter cloth layer is disposed away from the face, and the antimicrobial nonwoven cloth layer is disposed close to the face; the mask belt is disposed on the side of the mask body and is used to closely fit the mask body to the face; the nose strip is disposed on the upper part of the mask body and is used to closely fit the mask body to the bridge of the nose; the material of the antimicrobial nonwoven cloth layer is the antimicrobial nonwoven cloth as stated above.

As a preferred embodiment, the mask belt is disposed on both sides of the mask body through earloop, headband or tie-on.

As a preferred embodiment, a protective goggle is further provided on the mask body.

The present invention can achieve the following beneficial effects over the prior art: the antimicrobial nonwoven cloth prepared by the preparation method of the present invention is processed into antimicrobial nonwoven cloth layer with an appropriate size for use in the mask. The antimicrobial nonwoven cloth layer can resist microbes in a centralized manner and the filter cloth layer in the mask body can effectively filter the dust particulates; moreover, the mask belt makes the face to fit closely to the mask body, to prevent air from passing through the gap, and the nose strip makes no air flow at the mask body and the bridge of the nose, and structurally promotes air to pass through various layers of the mask body for sterilization and filtration and then enter the mouth and nose, which prevents bacteria from spreading through the air and saliva and achieves the preventive effect.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a structural representation of a mask with an earloop mask belt disposed on the mask body in the present invention;

FIG. 2 is a structural representation of a mask with a headband mask belt disposed on the mask body in the present invention;

FIG. 3 is a structural representation of a mask with a tie-on mask belt disposed on the mask body in the present invention;

FIG. 4 is a structural representation of a mask with a protective goggle disposed on the mask body in the present invention.

DETAILED DESCRIPTION

The present invention will be further described below in conjunction with specific embodiments. The following embodiments are merely used to illustrate the technical solutions more clearly rather than limit the scope of protection of the present invention.

Example 1

An antimicrobial nonwoven cloth, whose raw materials comprising the following components in weight ratio: 75˜100 parts of polypropylene, 10˜25 parts of sodium p-styrenesulfonate, 10˜20 parts of silane coupling agent, 0.15˜1 part of PHMB, 0.05˜0.4 part of zinc salt, 1˜5 parts of bamboo charcoal fiber, and 0.01˜0.1 part of nano-meter fumed silica.

Specifically, polyhexamethylene biguanide (PHMB) has a broad spectrum of bactericidal activity, low effective concentration, fast action speed, stable properties, and is easily soluble in water. It can be used at room temperature for long-term bacteriostasis. It has no side effects, no corrosivity, and is colorless, odorless, non-toxic, non-flammable, non-explosive, safe to use, so it is the best antimicrobial in practice. The antimicrobial effects of PHMB: 0.02% PHMB has an antimicrobial rate of 100% against Escherichia coli; 0.02% PHMB has an antimicrobial rate of 100% against Staphylococcus aureus; 0.02% PHMB has an antimicrobial rate of 100% against Candida albicans; 0.02% PHMB has an antimicrobial rate of 100% against Neisseria gonorrhoeae. The on-site antimicrobial test showed an antimicrobial rate of 99.8% on the surface of objects, which was greater than the national standard of 90%. The on-site antimicrobial test showed an antimicrobial rate of 97.65% on the palm surface, which was greater than the national standard of 90%. Therefore, PHMB used in the present invention has obvious antimicrobial effect, and has the killing ability against Gram-positive bacteria, Gram-negative bacteria, fungi (a variety of ringworms and molds) and yeasts.

Zinc ion (Zn) is involved in the activities of a number of enzymes related to human health. Zinc itself has astringent, antibacterial, anti-dandruff, and protective effects. Zinc ion is involved in the differentiation of epithelial tissues, with the anti-inflammatory effects. In addition, zinc ion can reduce UV-induced cell and gene damage, and improve the tolerance of skin fibroblasts to oxidative stress responses. Therefore, zinc salt and PHMB are used together in the present invention.

As a carrier, polypropylene (PP) has low density, good heat resistance, high strength, and chemical stability. It is a translucent and colorless solid, odorless and non-toxic. PP, as a carrier, is light in weight, good in heat retention and has very low hygroscopicity. Its moisture regain is almost close to zero under general atmospheric conditions, but it has a wicking effect and can transmit water vapor through the capillary in the fabric, while it does not absorb any moisture.

Example 2

The present invention further provides a method of preparing an antimicrobial nonwoven cloth, comprising the following steps:

(1) Weighing: Weighing the following components in weight ratio: 75˜100 parts of polypropylene, 10˜25 parts of sodium p-styrenesulfonate, 10˜20 parts of silane coupling agent, 0.15˜1 part of PHMB, 0.05˜0.4 part of zinc salt, 1˜5 parts of bamboo charcoal fiber, and 0.01˜0.1 part of nano-meter fumed silica;

(2) Heating the weighed aqueous solution of polypropylene, sodium p-styrenesulfonate, silane coupling agent in a water bath to 60±2° C., keeping warm and stirring for 2.5±0.5 h, and carrying out UV irradiation for 15±2 min and then cooling to 25±2° C. to obtain a polypropylene mixture;

(3) Preparing a composite solution using the weighed PHMB and zinc salt by the aqueous reaction method, then adding nano-meter fumed silica to obtain a composite antimicrobial agent; of which, using PHMB of different viscosity averaged relative molecular weights as a ligand, and adding zinc salt at a ratio of 5-6% to synthesize a stable micron-sized Zn-PHMB cationic complex from agglomerated small particles;

(4) Mixing the polypropylene mixture obtained in step (2) with bamboo charcoal fiber at 45±5° C. and stirring for 1±0.5 h, then adding the composite antimicrobial agent in step (3), stirring for 20±5 min and then standing for 1.5±0.5 h to obtain antimicrobial fiber solution, and then spinning to obtain antimicrobial nonwoven cloth fiber;

(5) Placing the antimicrobial nonwoven cloth fiber in step (4) on a mold for positioning and arrangement, and heat-pressing to form a fiber network structure;

(6) Adding anionic polyacrylamide solution as sizing liquid in the sizing machine, immersing the antimicrobial nonwoven cloth fiber web into the slurry with a temperature of 90±5° C. at a speed of 70±5 m/min, and then entering a drying room at a temperature of 135±5° C. for drying;

(7) After the sized and dried antimicrobial nonwoven cloth fiber web undergoes open-width treatment, performing desizing twice, washing out with warm water, and spraying ozone oil onto the web;

(8) Drying the desized fiber web qualitatively to prepare an antimicrobial nonwoven cloth product.

Specifically, the antimicrobial nonwoven cloth prepared by the method has strong antimicrobial function, moisture absorption and perspiration comfort. The antimicrobial nonwoven cloth is suitable for making the antimicrobial nonwoven cloth layer of the mask, and the prepared mask is antibacterial, comfortable, non-toxic and odorless and flame retardant, so it is the first choice to prevent cross infection.

Preferably, the steps for preparing the bamboo charcoal fiber are as follows:

(1) Performing cleaning the raw material moso bamboo, and drying it at a temperature of 50±5° C. in a sterile environment, then evenly cutting and placing it in a carbonization furnace;

(2) Carrying out carbonization in a carbonization furnace under a pure oxygen high temperature environment by setting the initial firing temperature of the carbonization furnace at 400±50° C. and the initial firing time at 1±0.5 h; setting the calcination temperature of the carbonization furnace at 850±50° C. and the calcination time at 3±0.5 h; using nitrogen with a purity of 98% for barrier during the carbonization process;

(3) Obtaining the carbonized bamboo charcoal fiber product.

Specifically, due to the addition of bamboo charcoal fiber, it is fully utilized to generate negative ions and far infrared rays during use, to achieve partial disinfection and sterilization, and increase the healthy negative ions in the air. The bamboo charcoal fiber made by this method is suitable for ordinary uses. With a smooth surface and a soft feel, excellent bacteriostasis, sterilization and hygroscopicity, and low cost, it can meet the requirements of various hygiene indexes.

Example 3

As shown in FIGS. 1-4, the present invention further provides a mask with antimicrobial nonwoven cloth, comprising a mask body 1, a mask belt 2, and a nose strip 3, the mask body 1 comprises at least one antimicrobial nonwoven cloth layer 11, and at least one filter cloth layer 12, and the antimicrobial nonwoven cloth layer 11 is bonded with the filter cloth layer 12, the filter cloth layer 12 is disposed away from the face, and the antimicrobial nonwoven cloth layer 11 is disposed close to the face; the mask belt 2 is disposed on the side of the mask body 1 and is used to closely fit the mask body 1 to the face; the nose strip 3 is disposed on the upper part of the mask body 1 and is used to closely fit the mask body 1 to the bridge of the nose; the material of the antimicrobial nonwoven cloth layer 11 is the antimicrobial nonwoven cloth of claim 1.

Preferably, the mask belt 2 is disposed on both sides of the mask body 1 through earloop, headband or tie-on.

Preferably, a protective goggle 4 is further provided on the mask body 1. Further, the protective goggle 4 adopts transparent lenses, and the lens material is PET (polyester film).

Preferably, the nose strip 3 is made of bendable ductile material or metal wire wrapped with plastic. The length of the nose strip 3 should not be less than 8.0 cm; the mask belt 2 is made of rubber string, and measured with a static tension of 10N for 5 seconds. The breaking strength at the connection point between each mask belt 2 and the mask body 1 is not less than 10N.

Specifically, when the mask of the present invention is used, the mask should be able to cover the mouth, nose and jaw of the wearer.

The antibacterial activity test was conducted for the mask of the present invention in accordance with GB/T20944.3-2008 Textiles-Evaluation for antibacterial activity—Part 3: Shake flask method. The results showed that the antibacterial rates against Candida albicans, Escherichia coli and Staphylococcus aureus all reached 99%.

The test of residual amount of ethylene oxide was conducted for the mask of the present invention in accordance with the method specified in Appendix G of GB15980-2003. The residual amount of ethylene oxide should be not less than 10 m/g.

The bacterial filtration efficiency was tested for the mask of the present invention. Three samples were randomly selected to conduct testing of bacterial filtration efficiency (the percentage of bacteria-containing suspended particles filtered by the mask material under a specified flow rate) according to the method in YY0469. The bacterial filtration efficiency was not less than 95%.

The airflow resistance test (the resistance of the mask under a specified area and a specified flow rate, expressed as a pressure difference) was performed on the mask of the present invention. Three samples were randomly selected to conduct testing. The middle part of the mask was taken and the gas flow rate was adjusted to (8±0.2) L/min; the diameter of the sample test area was 25 mm, and the test area of the test sample was A. The pressure difference on both sides of the mask was measured by a differential pressure gauge or equivalent equipment, and the airflow resistance was calculated according to the formula ΔP=M/A, where ΔP was the pressure difference per square centimeter of the test sample, in unit of Pa/cm2; M was the pressure difference of the test sample, in unit of Pa, A was the test area of the test sample, in unit of square centimeter (cm2). The airflow resistance for gas exchange on both sides of the mask was not more than 9 Pa/cm2.

The above descriptions are merely the preferred embodiments of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the technical principles of the present invention, improvements and modifications can be made, and these improvements and modifications shall fall into the scope of protection of the present invention. 

1. An antimicrobial nonwoven cloth, whose raw materials comprising the following components in weight ratio: 75˜100 parts of polypropylene, 10˜25 parts of sodium p-styrenesulfonate, 10˜20 parts of silane coupling agent, 0.15˜1 part of PHMB, 0.05˜0.4 part of zinc salt, 1˜5 parts of bamboo charcoal fiber, and 0.01˜0.1 part of nano-meter fumed silica.
 2. A method of preparing an antimicrobial nonwoven cloth, comprising the following steps: (1) Weighing: Weighing the following components in weight ratio: 75˜100 parts of polypropylene, 10˜25 parts of sodium p-styrenesulfonate, 10˜20 parts of silane coupling agent, 0.15˜1 part of PHMB, 0.05˜0.4 part of zinc salt, 1˜5 parts of bamboo charcoal fiber, and 0.01˜0.1 part of nano-meter fumed silica; (2) heating the weighed aqueous solution of polypropylene, sodium p-styrenesulfonate, silane coupling agent in a water bath to 60±2° C., keeping warm and stirring for 2.5±0.5 h, and carrying out UV irradiation for 15±2 min and then cooling to 25±2° C. to obtain a polypropylene mixture; (3) preparing a composite solution using the weighed PHMB and zinc salt by the aqueous reaction method, then adding nano-meter fumed silica to obtain a composite antimicrobial agent; of which, using PHMB of different viscosity averaged relative molecular weights as a ligand, and adding zinc salt at a ratio of 5˜6% to synthesize a stable micron-sized Zn-PHMB cationic complex from agglomerated small particles; (4) mixing the polypropylene mixture obtained in step (2) with bamboo charcoal fiber at 45±5° C. and stirring for 1±0.5 h, then adding the composite antimicrobial agent in step (3), stirring for 20±5 min and then standing for 1.5±0.5 h to obtain antimicrobial fiber solution, and then spinning to obtain antimicrobial nonwoven cloth fiber; (5) placing the antimicrobial nonwoven cloth fiber in step (4) on a mold for positioning and arrangement, and heat-pressing to form a fiber network structure; (6) adding anionic polyacrylamide solution as sizing liquid in the sizing machine, immersing the antimicrobial nonwoven cloth fiber web into the slurry with a temperature of 90±5° C. at a speed of 70±5 m/min, and then entering a drying room at a temperature of 135±5° C. for drying; (7) after the sized and dried antimicrobial nonwoven cloth fiber web undergoes open-width treatment, performing desizing twice, washing out with warm water, and spraying ozone oil onto the web; (8) drying the desized fiber web qualitatively to prepare an antimicrobial nonwoven cloth product.
 3. The method for preparing antimicrobial nonwoven cloth according to claim 2, wherein the steps for preparing the bamboo charcoal fiber are as follows: (1) performing cleaning the raw material moso bamboo, and drying it at a temperature of 50±5° C. in a sterile environment, then evenly cutting and placing it in a carbonization furnace; (2) carrying out carbonization in a carbonization furnace under a pure oxygen high temperature environment by setting the initial firing temperature of the carbonization furnace at 400±50° C. and the initial firing time at 1±0.5 h; setting the calcination temperature of the carbonization furnace at 850±50° C. and the calcination time at 3±0.5 h; using nitrogen with a purity of 98% for barrier during the carbonization process; (3) obtaining the carbonized bamboo charcoal fiber product.
 4. A mask with antimicrobial nonwoven cloth, comprising a mask body, a mask belt, and a nose strip, the mask body comprises at least one antimicrobial nonwoven cloth layer, and at least one filter cloth layer, and the antimicrobial nonwoven cloth layer is bonded with the filter cloth layer, the filter cloth layer is disposed away from the face, and the antimicrobial nonwoven cloth layer is disposed close to the face; the mask belt is disposed on the side of the mask body and is used to closely fit the mask body to the face; the nose strip is disposed on the upper part of the mask body and is used to closely fit the mask body to the bridge of the nose; the material of the antimicrobial nonwoven cloth layer is the antimicrobial nonwoven cloth of claim
 1. 5. The mask according to claim 4, wherein the mask belt is disposed on both sides of the mask body through earloop, headband or tie-on.
 6. The mask according to claim 4, wherein a protective goggle is further provided on the mask body.
 7. The mask according to claim 5, wherein a protective goggle is further provided on the mask body. 